Flintec MCS-64 User Manual

MCS-64

(Multi Channel System for Process Industry)

Manual MCS-6 with Modbus on Ethernet

FUSE

5X20

Y 5

V+

PWR

PGM 86.1

Com

6 5 4 3 2 1

PB Adresse

Act

Profibus Connector

FLINTEC

www.flintec.com

Example of MCS-64 with 5 channels and Profibus-Gateway

C0123C C0123C

PWR

Com

In 0

In 1

In 2

In 3

Out 0

Out 1

Out 2

Out 3

Err

Sig+

Sen+

Exc+

PWR

Com

LDM 88.1

Exc-

Sen-

Sig-

LDM 88.1

In 0

In 1

In 2

In 3

Out 0

Out 1

Out 2

Out 3

Err

Exc-

Sen-

Sig-

Sig+

Sen+

Exc+

Logic out

Logic in

470uF

+HP

Load Cells

FLINTEC Fl112081 B16

Mt1

ON DIP

1234

FLINTECFl112081 B16

FLINTEC

www.flintec.com

Exc+

Mt27

PWR

Com

In 0

In 1

In 2

In 3

Out 0

Out 1

Out 2

Out 3

Err

Sen+

C0123CC0123CC0123C C0123C

Mt2

Logic out

Logic in

J14

470uF

+HP

LDM 88.1

PWR

Com

In 0

In 1

In 2

In 3

Out 0

Out 1

Out 2

Out 3

Err

LDM 88.1

PWR

Com

In 0

In 1

In 2

In 3

Out 0

Out 1

Out 2

Out 3

Err

LDM 88.1

T26

Load Cells

Mt28

Exc-

Sen-

Sig-

Sig+

Sen+

Exc+

Exc-

Sen-

Sig-

Sig+

Sen+

Exc+

Exc-

Sen-

Sig-

Sig+

Sen+

Exc+

Exc-

Sen-

Sig-

Sig+

Document no. G165-Rev1-GB

www.flintec.com

Manual MCS-64 Page 1

Components of MCS-64 in overview

Base Board

MB 89.1

LDM 88.1

CGM 85,1

Load Cell

#64

LDM 88.1

RS485 - Bus

LDM 88.1

#64

RS 232

Service-Port

Gateway

- Profibus (PGM 68.1)

- CANopen (CGM 85.1)

- Ethernet (EGM 87.1)

Components of MCS-64

All boards have the same technical features:

Spring clips for load cell terminals in 6-wire-technique

•

• 4 DI’s via spring clip terminal blocks

•

4 DO’s via spring clip terminal blocks

Fieldbus

Extension Boards

MB 89.2 MB 89.3 MB 89.4

PGM 86.1

MB 89.1

EGM 87,1

•

Slot for one Gateway CGM 85.1 / PGM 86.1 / EGM 87.1

•

2 Slots for weighing processor LDM 88.1

•

RS 232 Service port

Extension Boards MB 89.2/.3/.4

•

2/4/8 Slots for weighing processor LDM 88.1

MB 89.2

MB 89.3

Base Board MB 89.1

Dim 104 x 135 mm

MB 89.4

Dim 79 x 135 mm

Dim 129 x 135 mm

Dimensions 229 x 135 mm

Page 2 Manual MCS-64 Ethernet

Weighing Processor LDM 88.1

Remote Control Output Start Filling Cycle

Trigger Signal

The digital weighing processor LDM 88.1 is a load cell digitizing unit for precise measuring of loads in motion.

± 18 bit resolution (±260 000 d)

•

Excitation5VDC/50mA

•

2 400 Measurements/s internal,

•

600 Measurements/s external mV/V calibration

•

4 DI’s

•

4DO’s

•

RS 485 bus, 115.2 kBaud

•

Digital Filter (FIR and IIR)

•

for static or dynamic weighing

•

processes 3 Firmware versions

•

LDM 88.1

Digital

Load Cell

Low-Pass

Filter

ADC

Digital Filter

IIR- / FIR

Input 1 ... 4

- Net

- Gros

- Average

- Dose

Digital Output / Setpoint 1 ... 4

binary format

RS 485 / 230 kBaud

LDM 88.1

LDM 88.1 Specifications

Linearity < 0.002 % FS Excitation 5 V DC, load cells 100-2 000 Ohm, 6 wire technique Analogue input range ±2.2 mV/V (bipolar) Minimum input per vsi 0.05 μV per interval non approved Resolution ±260 000 counts , ±18-Bit-A/D convertor Conversion rate 2400 measurements per second intern Digital Filter FIR Filter 2.5 ... 19.7 Hz or IIR Filter 0.25 ... 18 Hz; programmable in 8 steps each Calibration software calibration and set up Computer interface intern RS485/RS422, full duplex, 115 200 Baud, bus capability up to 64 devices Weighing functions zero, gross, tare, net, filter etc. Inputs 4 opto-isolated inputs, 10 ... 30 V DC max. 3 mA Outputs 4 OC outputs, < 35 V DC, 500 mA Temperature effects on zero 5 ppm/°K typ.; max. < 10 ppm/°K

Temperature range –10 °C to +50 °C (operating); –30 °C to +80 °C (storage) Enclosure Aluminium, protection IP40 Dimensions 80 x 23 x 100 mm, with two M3 fixing screws for mounting on boards MB89.1/2/3/4 Power supply 12 ... 24 V DC ±10 %, < 60 mA,(reversed voltage, burst and ESD protected) Power consumption 1,5 W max. EMC CE 73/23/EEC; 93/98/EEC and 89/336/EEC Computer interface via Service Port MB 89.1 RS232C, 115 200 Baud Vibration withstands 1.0 G operational; 2.5 G non-operational

on span 4 ppm/°K typ.; max. < 8 ppm/°K

Manual MCS-64 Ethernet Page 3

Contents

Part A: Modbus on Ethernet.........................................................................................pages 6 - 13

Part B: Commands......................................................................................................pages 14 - 35

Part C: MCS-64 Components and Configuration........................................................pages 36 - 45

Introduction...........................................................................................................................6

1.1. Identification and Scope ................................................................................................6

1.2. Purpose .........................................................................................................................6

2. System Design......................................................................................................................6

2.1 General..........................................................................................................................6

2.2 Backplane handling.......................................................................................................6

2.3 Ethernet Gateway..........................................................................................................7

2.3.1 IP Settings.................................................................................................................7

2.3.2 The Modbus port .......................................................................................................7

2.3.3 The ASCII entry port..................................................................................................7

3 Ethernet Gateway Profile.....................................................................................................8

3.1 The Modbus Objects .....................................................................................................8

3.2 Communication Profile ..................................................................................................8

4 Modbus Mapping..................................................................................................................9

4.1 Modbus Register Map Overview ...................................................................................9

4.1.1 Gateway Register Map..............................................................................................9

4.1.2 LDM Register Map...................................................................................................10

5 COMMANDS........................................................................................................................14

5.1 System diagnosis – ID, IV, IS......................................................................................15

5.2 Calibration Commands – CE, CM, CI, DS, DP, CZ, CG AZ, AG, ZT, FD, CS.............16

5.3 Motion detection Commands – NR, NT.......................................................................20

5.4 Filter setting Commands – FM, FL, UR.......................................................................21

5.5 Set Zero/Tare and Reset Zero/Tare Commands – SZ, RZ, ST, RT............................23

5.6 Output Commands – GG, GN, GT, GS.......................................................................25

5.7 Setpoint Commands - Sn, Hn, An ...............................................................................26

5.8 Trigger Commands – SD, MT, GA, TE, TR, TL...........................................................28

5.9 Trigger Special Commands– RW, TT, TS, DT, TW, TI, HT.........................................31

5.10 Save calibration, setup and setpoint parameters Commands – CS, WP, SS .............34

5.11 Filling Commands – PD1 to PD21, DI, SC, AC, GD, DT, SD......................................35

5.12 Loss in Weight Commands – PL1 to PL5, LC, LI, GF, GR, GM, SL...........................35

5.13 Speed Estimation Multi-Channel System MCS-64......................................................35

Page 4 Manual MSC-64: Modbus on Ethernet

6 MCS-64 Components and Configuration..........................................................................36

6.1 Base Board MB 89.1 for 1 Gateway and 2 LDM 88.x..................................................36

6.2 Extension Board MB 89.2 for 2 LDM 88.x...................................................................37

6.3 Extension Board MB 89.3 for 4 LDM 88.x...................................................................38

6.4 Extension Board MB 89.4 for 8 LDM 88.x...................................................................39

6.5 Address setup guide extension boards for 1 – 16 channels........................................40

6.6 Address setup guide extension boards for up to 32 channels.....................................41

6.7 Example Check Weigher Wiring ..................................................................................42

6.8 Example Liquid Filling Wiring ......................................................................................43

6.9 LDM 88.1 – Digital Input / Digital Output -...................................................................44

6.10 Firmware Versions.......................................................................................................45

6.11 DOP software for Windows 2000/XP...........................................................................45

Manual MCS-64: Modbus on Ethernet

Page 5

1. INTRODUCTION

1.1. Identification and Scope

This document describes the system design for the Modbus on Ethernet (EGM 87.1) and up to 64 Load Cell Digitizing Modules (LDM88.x) using the Flintec backplane system. It describes the functionality of the backplane, the protocol used on the backplane and the Modbus mapping used to access the LDM88 modules via the EGM87 Gateway.

1.2. Purpose

The purpose of this document is to specify functionality and performance of the Gateway and the Load Cell Digitizing Modules (LDM88) with the available firmware versions (standard 88.183, filling 88.184, loss in weight 88.185).

2. SYSTEM DESIGN

2.1 General

This software connects an Ethernet network to the local backplane modules. The Gateway transports commands and responses from and to the Ethernet.

Ethernet

ADAPTOR

LDM an d other IO

Up to 64 modules per backplane

BACKPLANE

Figure 1- ETHERNET Gateway in context

2.2 Backplane handling

The Gateway translates Modbus requests to local backplane requests and local backplane responses to Modbus responses. The Modbus is currently fixed to port 502 using an UDP/IP connection. Multiple register access through the Ethernet will produce multiple accesses on the local backplane. The PLC response timeout must allow 3.125 ms for each register access required. However reading registers 2000 or 2004 will cache register 2060 also allowing the PLC to acquire the corresponding qualifier to the weight values.

Page 6 Manual MSC-64: Modbus on Ethernet

2.3 Ethernet Gateway

The Ethernet Gateway is using a 10/100baseT on RJ45 connection (IEEE 802.3u standard). The Gateway is essentially a server waiting for a node to connect to one of its services.

Application stacks:

Modbus Application Layer Setup Port 502 Port 502 Port 23 MBAP MBAP TCP UDP TCP IP IP IP

802.3 802.3 802.3

System stacks:

(echo / ping) (Dynamic IP addr.) (Address Resolution) ICMP DHCP IP IP ARP

802.3 802.3 802.3

2.3.1 IP Settings

The IP address is set by connecting a terminal program (e.g. HyperTerm) to the DB9 service port on the MB 89.1 Base board. After the system is powered up it is possible to communicate with the Ethernet Gateway Module (EGM). After openening the gateway with command "OP 64" it is possible to set and/or examine the gateway settings with the address command:

Command op64 opens serial communication to the gateway ai 192.168.1.29 sets the gateway’s IP address to “192.168.1.29” ai selects a dynamic IP address (DHCP) for the gateway a reads current MAC address and IP address of the gateway

Example:

op64 OK a mac=00:50:C2:70:50:62 ip= DHCP

2.3.2 The Modbus port

[Port 502, TCP/IP (Modbus) or UDP/IP (Modbus)] The Modbus is a simple Master-Slave connection; the master asks and the slave answers. Modbus over TCP or UDP is just another way of transporting Modbus communication. One of the registers will be used to define a streaming port. When a client connects to this user-defined port the gateway will scan the backplane and transmit the LDM data on a regular basis. See Chapter 3 “Ethernet Gateway Profile” below.

2.3.3 The ASCII entry port

[Port 23, TCP/IP (Telnet)] This entry is for simple setup and diagnostic use. It works as if you were connected to the service port except it goes through the Ethernet. The HyperTerm program in Windows can access the gateway in this manner. Refer to LDM 88.1 commands, see chapter 5.

Manual MCS-64: Modbus on Ethernet

Page 7

3 ETHERNET GATEWAY PROFILE

3.1 The Modbus Objects

All parameters and result data can be accessed in this way. Please note that many of the registers in the 2000 – 20FF range require a local backplane access cycle per register. Reading multiple registers in this range may produce a very long response time. Below is the preliminary Modbus Map.

3.2 Communication Profile

The parameters which are critical for communication are determined in the communication profile. This includes the data for manufacturer's product nomenclature, for identification, or the parameters for object mapping.

Abbreviations used in the tables: R = read only R/W = read / write W = write only (read will not be regarded as an error, but returns undefined results) UI16 = Unsigned16 (single register) UI32 = Unsigned32 (register pair) Int16 = Signed16 (single register) Int32 = Signed32 (register pair) Float = 32 bit IEEE754 floating point (register pair)

Page 8 Manual MSC-64: Modbus on Ethernet

4 MODBUS MAPPING

The MBAP header “Unit Identifier” field is used to select a module in the backplane. Address 0 (zero) is reserved for broadcast. Address 1 to 64 is then used for direct communication with any LDM in the backplane using registers in the range 2000-2FFF (hex). Access to the gateway should use address 0xFF (255 dec) and registers in the range 3000-3FFF(hex).

Currently implemented function codes are: Access

03 Read Holding Registers 04 Read Input Registers 06 Write Single Register 16 Write Multiple Registers

Used exception codes are: Meaning

01 Illegal or unkown function code 02 Illegal data address or no response from LDM

4.1 Modbus Register Map Overview

4.1.1 Gateway Register Map

Register Type Size Access Function 3000 Int16 1 R/W LDM selector [0..63] 3001 Int16 1 R/W LDM multiple register selector. 3002 Int16 1 R/W LDM multiple register mode 3003 – 300F - - (reserved) 3005 Int16 1 R/W Auto-Scan Control/Status

3006 Int16 1 R/W Auto-Scan Port (IP port no.) 3007 Int32 2 R/W Auto-Scan Interval (ms) 3009 – 30FF (reserved) 3100 – 31FF R/W Multiple register access across multiple LDM modules. 3200 – 32FF Float 2+2+1 R Multiple read of LDM packets 3300 – 33FF Integer 2+2+1 R Multiple read of LDM packets

Bit: 15 10 9 2 1 +------------+--------+-----+ | Last scan | unused | R/S | +------------+--------+-----+

Manual MCS-64: Modbus on Ethernet

Page 9

4.1.2 LDM Register Map

The register map for each LDM.

LDM overview

Register Type Size Access Function 2000 – 201F Float 08 * 2 R/W Data in Float Format 2020 – 205F Int32 16 * 2 R/W Data in Integer Format 2060 – 207F Int16 08 * 1 RW Control/Status functions 2080 – 20FF (reserved) 2100 – 2FFF - - R/W Parameter pages

Data in Float Format

Register Type Size Access Data in Float Format 2000 Float 2 R Gross weight 2002 Float 2 R Net Weight 2004 Float 2 R/W Tare 2006 Float 2 R Dosed weight 2008 Float 2 R Average weight

Data in Integer Format

Register Type Size Access Data in Integer Format 2020 Int32 2 R Gross weight 2022 Int32 2 R Net Weight 2024 Int32 2 R/W Tare 2026 Int32 2 R Dosed weight 2028 Int32 2 R Average weight 202A Int32 2 R A/D sample 202C Int32 2 R Device ID 202E Int32 2 R FW Version 2030 Int32 2 R Device Status 2032 Int32 2 R ADC Reference

Control/Status Functions

$0001 - Under range $0002 - Over range $0004 - Not within Zero range (not yet implemented, zero) $0008 - Exactly zero $0010 - No motion, still stand, steady state $0020 - Tare set $0040 - Preset tare (0=tare is measured, 1=tare is set by user) $0080 - Invalid weighing (wire-break, A/D ref. out of range) $0100 - Set-point 0 (source>limit) $0200 - Set-point 1 $0400 - Set-point 2 $0800 - Set-point 3 $1000 - Filling in progress $2000 - Filling has completed $4000 - Average ready $8000 - Cold start

Page 10 Manual MSC-64: Modbus on Ethernet

2061 Int16 1 R/W Bit commands. Functions regardless of the setting of the LDM

selector register. Bit 1: Reset Zero (RZ)

Bit 2: Set Zero (SZ) Bit 3: Reset Tare (RT) Bit 4: Set Tare (ST) Bit 5 – 7: unused Bit 8 –15: LDM#

Write a “1” to activate function, reads as “1” until command done

2062 Int16 1 R/W Trigger: Functions regardless of the setting of the LDM selector

2063 Int16 1 R/W Parameter page select. Valid values= [0..4].

General parameter values Calibration parameter values Filling parameter values Check weigher parameter values Mass flow parameter values

2064 Int16 1 R/W TAC access, see calibration page. 2065 Int16 1 R/W START / ABORT filling process.

Writing a Non-zero value starts filling process. Writing a zero ABORTS filling process.

2066 Int16 1 R/W EEPROM functions:

Bit 1: Save analogue parameters (AS) Bit 2: Save calibration (CS); TAC protected Bit 3: Save general setup parameters (WP) Bit 4: Save dosing parameters (SD) Bit 5: Save setpoint parameters (SS) Bit 6 –14: unused

Bit 15: Factory default; TAC protected 2067 Int16 1 R/W Set-point select [0..3] 2068 Int32 2 R/W Set-point source 206A Int32 2 R/W Set-point hysteresis 206C Int32 2 R/W Set-point Value 206E Int16 1 R Read the dose info:

Bit value Meaning $0001 Coarse valve open $0002 Fine valve open $0004 Dose program running $0008 Not used $0010 Not used $0020 Not used $0040 Tare out of range – no filling in this cycle $0080 Zero out of range $FF00 The High byte has the following interpretation:

00= Idle 01= Waiting for trigger(2

trigger) 02= Bottle on, calculating tare 03= Pre-fill 04= Main Filling 05= Fine Filling 06= In-flight delay 07= Post fill calculations 08= Post Filling

Manual MCS-64: Modbus on Ethernet

Page 11

Page 0 – General Parameter Values

2100 Int32 2 R/W Analog action 2102 Int32 2 R/W Analog high 2104 Int32 2 R/W Analog low

2106 Int32 2 R/W Filter setting

2108 Int32 2 R/W Filter Factor 210A Int32 2 R/W Output status 210C Int32 2 R/W Input mask

210E Int32 2 R/W Measuring Time 2110 Int32 2 R/W Filter mode 2112 Int32 2 R/W No-motion range 2114 Int32 2 R/W No-motion time 2116 Int32 2 R/W Output mask 2118 Int32 2 R/W Tare 211A Int32 2 R/W Start Delay 211C Int32 2 R/W Trigger Edge 211E Int32 2 R/W Trigger Level 2120 Int32 2 R/W Update rate 2122 Int32 2 R/W Zerotrack (TAC protected) 2124 Int32 2 R/W dtime

Page 1 – Calibration Parameter Values

Register Type Size Access Calibration parameter values 2200 Int32 2 R/W Absolute gain calibrate (32 bit Integer) 2202 Int32 2 R/W Absolute zero calibrate (TAC protected) 2204 Int32 2 R/W Calibrate enable 2206 Int32 2 R/W Calibrate gain (TAC protected)

2208 Int32 2 R/W Set calibration point B 220A Int32 2 R/W Set calibration point A

220C Int32 2 R/W Calibrate max (TAC protected) 220E Int32 2 R/W Calibrate min (TAC protected) 2210 Int32 2 R/W Calibrate save (TAC protected) 2212 Int32 2 R/W Calibrate zero (TAC protected) 2214 Int32 2 R/W Decimal point (TAC protected) 2216 Int32 2 R/W Display step size (TAC protect)

Page 2 - Filing Parameter Values

Register Type Size Access Filling parameter values 2300 Int32 2 R/W Pre-fill mode 2302 Int32 2 R/W Correction factor for in-flight value 2304 Int32 2 R/W Zero Check Time 2306 Int32 2 R/W Tare delay 2308 Int32 2 R/W Tare Average Time 230A Int32 2 R/W Delay after pre-fill 230C Int32 2 R/W Blanking time 230E Int32 2 R/W In-flight delay time 2310 Int32 2 R/W Filling Weight Average Time 2312 Int32 2 R/W Zero tolerance 2314 Int32 2 R/W Tare reference 2316 Int32 2 R/W Tare tolerance 2318 Int32 2 R/W Pre-fill level 231A Int32 2 R/W Fine-fill weight 231C Int32 2 R/W Filling weight 231E Int32 2 R/W In-flight value

Page 12 Manual MSC-64: Modbus on Ethernet

Register Type Size Access Filling parameter values 2320 Int32 2 R/W Secondary pre-fill level 2322 Int32 2 R/W Timeout value in milliseconds 2324 Int32 2 R/W Underweight post-fill time 2326 Int32 2 R/W Tare interval 2328 Int32 2 R/W Bag Rupture Blanking

Page 3 – Check Weigher Parameter Values

Register Type Size Access Checkweigher parameter values 2400 Int32 2 R/W Trigger Level 2402 Int32 2 R/W Trigger Edge 2404 Int32 2 R/W ReTrigWindow 2406 Int32 2 R/W ReTrigTime 2408 Int32 2 R/W HoldTime 240A Int32 2 R/W TareWindow 240C Int32 2 R/W TareTime 240E Int32 2 R/W ReTrigStop 2410 Int32 2 R/W Measuring time 2412 Int32 2 R/W Start delay 2414 Int32 2 R/W dTime

Page 4 - Mass Flow Parameter Values

d/sec d/min d/hour x1 0 1 2 x1.000 3 4 5 x1.000.000 6 7 8

2504 Int32 2 R/W dTime 2506 Int32 2 R/W dWeight 2508 Int32 2 R/W Delay after Refill

Page 5 - Mass Flow Control Values

Page 6 - Mass Flow Results

Register Type Size Access Mass Flow parameter values 2700 Float 2 R Mass Flow Value 2702 Float 2 R Mass Flow Trend 2704 Float 2 R Total Mass

Manual MCS-64: Modbus on Ethernet

Page 13

Part B

5 COMMANDS

These pages describe the ASCII commands as they must be used by the DOP software. For each command the corresponding Modbus register and data types are shown in brackets [ ] for reference.

5.1

System diagnosis – ID, IV, IS......................................................................................15